Mitsubishi Lancer Evolution 8 2003-2005 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo 8 Production Years Covered: 2003-2005 Codes Chassis Code Prefix: CT9A 👋 Introduction Market Position Segment: Performance Compact Sedan / Rally Homologation Special Target Audience: Enthusiast drivers, performance vehicle owners, tuners, mechanics specializing in performance vehicles Competitive Analysis Key Rivals: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (later generations), Volkswagen Golf R Key Features Engine Performance: Legendary 4G63T engine known for its robustness and tuning potential Drivetrain: Symmetrical All-Wheel Drive (SAWD) with Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) for exceptional traction and handling Braking System: High-performance Brembo brakes as standard equipment Aerodynamics: Aggressive aerodynamic package including large rear wing, front lip spoiler, and vented hood Suspension: Performance-tuned suspension for sharp handling and track-ready capabilities 📋 Manual Details Coverage Areas Scope: Comprehensive service, maintenance, and repair for Mitsubishi Lancer Evolution VIII Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: 4G63T (2.0L Turbocharged Inline-4) - Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, valve train, timing system, lubrication system, cooling system, intake system, exhaust system Engine Electrical: Ignition system, fuel injection system (ECU, sensors, injectors), emissions control, starter motor, alternator, wiring diagrams, diagnostic trouble codes (DTCs) Transmission: 6-speed manual transmission (Type R) - Gearbox assembly, clutch system, driveline, transfer case, ACD (Active Center Differential) system, rear differential Suspension: Front MacPherson struts, Rear multi-link suspension, anti-roll bars, bushings, alignment specifications Brakes: Front Brembo 4-piston calipers, Rear Brembo 2-piston calipers, brake fluid specifications, bleeding procedures, ABS (Anti-lock Braking System) components and diagnostics Steering: Power assisted rack and pinion steering system, steering column, tie rods, steering knuckle Body And Chassis: Body construction, panels, doors, hood, trunk, bumpers, exterior trim, interior trim, noise insulation, chassis stiffening components Electrical And Accessories: Lighting systems (headlights, taillights, interior), power windows, central locking, climate control system, audio system, instrument cluster, wipers and washers, horn Heating Ventilation Air Conditioning: HVAC system components, refrigerant, troubleshooting, repair of evaporator, condenser, blower motor, control panel Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel pressure regulator, injectors, fuel system diagnostics Procedures Included Maintenance: Routine maintenance schedules, oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and changes (coolant, brake fluid, transmission fluid, differential fluid), belt inspections and replacement Troubleshooting: Diagnostic flowcharts for common and uncommon problems, identification of symptoms, root cause analysis for engine performance, electrical faults, transmission issues, brake problems, and HVAC malfunctions Repair And Rebuild: Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Includes engine rebuild, transmission overhaul, brake caliper rebuilding, suspension component replacement, body panel repair, and electrical component repair. Diagnostics: OBD-II diagnostics, sensor testing, actuator testing, live data interpretation, specific diagnostic procedures for the 4G63T engine and related ECUs Specifications And Tolerances: Torque specifications for all fasteners, engine clearances, valve lash, fluid capacities, electrical resistance values, and other critical tolerances for accurate repair and assembly. Technical Depth Depth: Extremely High - Covers everything from basic scheduled maintenance and fluid changes to complex engine and transmission rebuilds, advanced electrical diagnostics, and bodywork. 📊 Manual Specifications File Format Format Type: PDF Searchability: Searchable text enabled for quick information retrieval Print Quality Quality: High-resolution scans for clear diagrams and text Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: Inline-4, DOHC, 16-valve, turbocharged and intercooled Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower SAE Net: 271 hp @ 6500 rpm (US Spec) Torque SAE Net: 273 lb-ft @ 3500 rpm (US Spec) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Sequential Multi-Port Fuel Injection (SMPI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Turbocharger: Mitsubishi TD05H-16G (or similar variant), twin-scroll 🔧 Transmission Standard Type: 6-speed Manual Transmission Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD) Rear Differential: Super Active Yaw Control (S-AYC) rear differential Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (refer to manual for specific Mitsubishi recommendations) Transfer Case Fluid: Refer to manual for specific Mitsubishi recommendations (often same as trans fluid) Rear Differential Fluid: Refer to manual for specific Mitsubishi recommendations (often GL-5 75W-90, check for LSD compatibility if applicable) 📐 Dimensions Exterior Length: 4430 mm (174.4 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2625 mm (103.3 in) Front Track: 1510 mm (59.4 in) Rear Track: 1505 mm (59.3 in) Weights Curb Weight: Approx. 1450 kg (3197 lbs) Gross Vehicle Weight Rating: Refer to vehicle VIN plate or manual Towing Capacity: Not Applicable (Designed for performance, not towing) 🛡️ Safety Features Ratings NHTSA Front Crash:...
Lighting systems (headlights, taillights, interior), power windows, central locking, climate control system, audio system, instrument cluster, wipers and washers, horn
Heating Ventilation Air Conditioning:
HVAC system components, refrigerant, troubleshooting, repair of evaporator, condenser, blower motor, control panel
Routine maintenance schedules, oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and changes (coolant, brake fluid, transmission fluid, differential fluid), belt inspections and replacement
Troubleshooting:
Diagnostic flowcharts for common and uncommon problems, identification of symptoms, root cause analysis for engine performance, electrical faults, transmission issues, brake problems, and HVAC malfunctions
Repair And Rebuild:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Includes engine rebuild, transmission overhaul, brake caliper rebuilding, suspension component replacement, body panel repair, and electrical component repair.
Diagnostics:
OBD-II diagnostics, sensor testing, actuator testing, live data interpretation, specific diagnostic procedures for the 4G63T engine and related ECUs
Specifications And Tolerances:
Torque specifications for all fasteners, engine clearances, valve lash, fluid capacities, electrical resistance values, and other critical tolerances for accurate repair and assembly.
Technical Depth
Depth:
Extremely High - Covers everything from basic scheduled maintenance and fluid changes to complex engine and transmission rebuilds, advanced electrical diagnostics, and bodywork.
📊 Manual Specifications
File Format
Format Type:
PDF
Searchability:
Searchable text enabled for quick information retrieval
Print Quality
Quality:
High-resolution scans for clear diagrams and text
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline-4, DOHC, 16-valve, turbocharged and intercooled
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower SAE Net:
271 hp @ 6500 rpm (US Spec)
Torque SAE Net:
273 lb-ft @ 3500 rpm (US Spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Multi-Port Fuel Injection (SMPI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Turbocharger:
Mitsubishi TD05H-16G (or similar variant), twin-scroll
🔧 Transmission
Standard
Type:
6-speed Manual Transmission
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD)
Rear Differential:
Super Active Yaw Control (S-AYC) rear differential
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 (refer to manual for specific Mitsubishi recommendations)
Transfer Case Fluid:
Refer to manual for specific Mitsubishi recommendations (often same as trans fluid)
Rear Differential Fluid:
Refer to manual for specific Mitsubishi recommendations (often GL-5 75W-90, check for LSD compatibility if applicable)
📐 Dimensions
Exterior
Length:
4430 mm (174.4 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2625 mm (103.3 in)
Front Track:
1510 mm (59.4 in)
Rear Track:
1505 mm (59.3 in)
Weights
Curb Weight:
Approx. 1450 kg (3197 lbs)
Gross Vehicle Weight Rating:
Refer to vehicle VIN plate or manual
Towing Capacity:
Not Applicable (Designed for performance, not towing)
🛡️ Safety Features
Ratings
NHTSA Front Crash:
4-Star (for 2004 model year, US)
NHTSA Side Crash:
5-Star (for 2004 model year, US)
IIHS Front Crash:
Good (for 2004 model year, US)
IIHS Side Crash:
Good (for 2004 model year, US)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD)
Traction Control:
Active Traction Control (ASC) and Active Stability Control (ASTC) available on some models/regions
Drivetrain Control:
ACD and AYC systems contribute to active safety through enhanced traction and stability
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
3-point front seatbelts with pretensioners and load limiters, 3-point rear seatbelts
Body Structure:
Reinforced body structure with crumple zones and safety cage
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio systems by Rockford Fosgate in some markets/trims
Navigation:
Not commonly equipped from the factory; typically aftermarket additions
Driver Assistance
ABS:
Standard on all models
Stability Control:
Available as Active Stability Control (ASTC) on certain trims/markets
Connectivity
Oem Connectivity:
Limited to basic power outlets and antenna for audio; no integrated Bluetooth or USB from factory
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 - 7,500 miles (6,000 - 12,000 km) or 6 months, depending on driving conditions (refer to manual for severe vs. normal)
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or annually
Fuel Filter Replacement:
Every 30,000 - 45,000 miles (48,000 - 72,000 km)
Spark Plug Replacement:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (iridium recommended)
Timing Belt Replacement:
Every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years (critical component, refer to manual for exact interval and related components like tensioner and water pump)
Fluid Specifications
Engine Oil Type:
Synthetic 5W-30 or 5W-40 recommended (API SN/SP, ACEA A3/B4)
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter change
Coolant Type:
Ethylene Glycol based, long-life, pink/red (Mitsubishi DiaQueen Super Long Life Coolant or equivalent)
Coolant Capacity:
Approx. 7.2 Liters (7.6 US Quarts)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendations, high-temp fluid recommended for performance driving)
Known Issues
Engine Wear:
Potential for piston ring land failure and oil burning in high-mileage or poorly maintained engines, connecting rod bearing wear
Turbocharger:
Oil seal failure, leading to smoke, or bearing failure due to lack of proper cool-down or lubrication
Clutch:
Wear of the clutch disc and pressure plate, especially under aggressive driving conditions. Clutch fork wear is also noted.
Acd/Ayc:
ACD pump failure, AYC hydraulic system leaks or pump issues can affect AWD performance.
Suspension:
Wear in bushings, ball joints, and wheel bearings, particularly on vehicles used for performance driving or track days.
📚 Vehicle History
Brand Heritage
Rally Origins:
Direct lineage from Mitsubishi's highly successful World Rally Championship (WRC) program
Model Evolution
Evolution Series:
Part of the iconic Lancer Evolution lineage, known for continuous development and performance enhancements
Evo 8 Introduction:
Introduced to global markets, including a significant North American debut
Evo 8 Variants:
GSR, RS (Rally Sport - often stripped down), SE (Special Edition)
Production
Manufacturing Location:
Japan (Mizushima Plant)
Production Period:
2003-2005 (for the Evolution VIII generation)
🏆 Awards & Recognition
Recognitions
Performance Acclaim:
Consistently praised by automotive journalists and enthusiasts for its handling, powertrain, and rally-bred performance
Performance Car Of The Year:
Received numerous awards and accolades from automotive publications during its production run, often topping 'best performance car' lists for its segment
Ratings
Track Capability:
Widely recognized as a capable track day car and autocross competitor in its stock form